Miller | KG217318 | Owner Manual | Miller D-64M WIRE FEEDER CE User manual

Miller D-64M WIRE FEEDER CE User manual
Miller
September
Form:
1996
OM-1 587E
Effective With Serial No. KG21 7318
OWNERS
MANUAL
CE
D-64M Wire Feeder
For
Type of
Input Power
Welding
Source
Power
Type
Constant Voltage (CV)
24 Volts AC
Single-Phase
10 Amperes
DC For GMAW Or
Constant
Voltage(CV) /
(CC) DC
Wire Feed
Speed Range
Standard: 50 To
780 1pm (1.3 To
19.8
mpm)
Wire
Welding
Diameter
Circuit
Range
Rating
.023 To 1/8 in
(0.6 To 3.2
100 Volts,
750
mm)
Constant Current
50/60 Hertz
For GMAW-P
All Need 14-Pin And
Contactor Control
cover_om 4/95
GMAW-P, GMAW, And FCAW Welding
ST-800 179
Optional High
Speed: 92 To
1435 ipm (2.3 To
36.5 mpm)
'
Amperes,
Duty
Cycle
100%
Max
Spool
Weight: 60 lb
(27 kg)
1996 MILLER Eleclnc
Mfg. Co.
IP
Overall
Rating
Dimensions
Weight
Length: 32 in
(812 mm)
23
Width: 18 in
78 lb
(457 mm)
(35 kg)
Height: 14 in
(356 mm)
PRINTED IN USA
u-f
a
MILLERS
I
TRUE BLUEfi LIMITED WARRANTY
(Equipment
with
Effective February 7, 1996
serial number preface of KD
This limited werrsnty supersedes all previous MILLER werrenties end is exclusive with
LIMITED WARRANTY
or
a
Subject to the terms end
conditions below, MILLER Electric
Mfg. Co., Appleton, Wisconsin, warrants to its original retell purchaser thst new
MILLER equipment sold efter the effective date ot this limited warranty is free of de
no
newer)
other guarantees
or
5.
6 Months
6.
9ODaysFsrtsendLsbor
fects in material end workmanship et the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
warranties
expressed
or
implied.
Batteries
MIG Guns/TIG Torches
IMPLiED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
-
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
-
Accessory Kits
NESS.
Remote Controls
Within the warrenty periods listed below, MILLER will repair or replace any war
ranted psrts orcomponents mat feil due to such defects in materiel or workmenship.
MILLER must be notified in
(30) deys of such defect
which time MILLER will
the warranty claim
writing within thirty
provide instructions on
Replacement
MILLERS
or failure, at
procedures to be
followed.
Iteme fumished
1.
Parts
True Bluefi Limited Warranty shell
by MILLER.
not
apply
but manufactured
trade accessories. These items em covered
to:
by others,
such
as
engines
or
by the menufacturars warranty, if
any.
MILLER shell honor warranty claims on warrenfed equipment listed below in the
failure within the warranty time penods. All warranty time periods
event of such a
Consumable components: such
2.
start on the date that the
equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North Amencan distributor or eighteen
months after the equipment is sent to en International distnbutor.
end
or
as
contact
pens that fsil due to normal
tips, cutting nozztes,
contectors
wear.
by any party other then MILLER, or equip
improperiy installed, improperiy operated or misused
industry standards, or equipment which hss not had reasonable
and necessary maintenance, or equipment which has been used for operation
outside of the specifications for the equipment.
Equipment
3.
1.
relays
thst has been modifIed
ment that has been
5YearaParts3YesrsLsbor
based upon
Original
main power rectifiers
Inverters
2.
-
(input
and output rectifiers
only)
MILLER PRODUCTS ARE INTENDED FOR PURCHASEAND USE BY COMMER
CIAIJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EGUIPMENT.
Parts and Labor
3 Years
Trsnsfom,er/Rectiflar Power Sources
-
Plasma Arc
-
Semi-Automatic end Automatic Wire Feeders
-
Inverter Power
Cutting
Power Sources
In the event of a warranty claim covered by this warranty, the exclusive remedies
shatl be, at MILLERS option: (1) rspeir~ or (2) replacement; or, where authorized in
writing by MILLER in appropnate csses, (3) the reasonable cost of mparror replace
ment at an authorized MILLER service station; or (4) payment of orcredit forthe pur
chase price (less reasonable depreciation based upon actual use) upon mtum of the
goods at customers risk and expense. MILLERS option of repair or replacement
will be FOB., Factory at Appleton. Wisconsin, or FOB. ate MILLER euthorised ser
Supplies
Intellitig
Robots (1 year
3.
2 Years
laborj
Parts end Labor
vice
Engine Driven Welding Generators
(NOTE: Engines are warranted sepersrely by
Air Compressors
4.
or
reimburse
engine manufacturer.)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVtDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENTSHALL MILLER BE
Parts end Labor
1 Year
facility as determined by MILLER. Therefore no compensation
transportation costs of any kind will be allowed.
ment for
the
UABLE FOR DIRECT, INDIRECT, SPECIAL, tNCIDENTALOR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
TRACT, TORT OR ANY OTHER LEGAL THEORY.
-
Motor Driven Guns
-
Process Controllers
IHPS Power Sources
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLtED WAR
-
Water Coolant
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
-
HF Units
-
Gnda
Spot
Systems
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLtCATtON,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEAUNG, IN
CLUDING ANY IMPUED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE. WITH RESPECTTO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER 5 EXCLUDED AND DISCLAIMED BY MILLER.
Welders
-
Load Banks
-
SDX Transformers
Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)
Tecumaeh Engines
Deutz Engines (outside North America)
Field Options
(NOTE: Field options are covered under True Bluefi for the remaining
Miller
-
-
-
warranty period of the product they
whichever is greater.)
one year
are
Some states in the U.S.A. do nor allow limitations of how long an implied warranty
lasts, or the exclusion of incidentsl. indirect, speciel or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides ape
legal righta, and other rights may be available, but may vary from state to state.
cit ic
In
Ceneda, legislation
in some
provinces provides for
certain additional warranties
stated herein, end to the extent that they may not be
waived, the limitations end exclusions set out above may not apply. This Limited
Warranty provides specific Iegsl rights, and other rights may be available, but may
vary from province to province.
or
installed in, or for a minimum of
~~1
remedies other than
as
I
WHO DO I CONTACT?
For
To file
help,
contact your distributor
U
For
additional
information,
Technical Manuals
Engine
a
claim for loss
such
contact the
as
(Service And Parts)
damage during
delivering
For assistance in
filing
or
manufactUrerS
Wiring Diagrams
Miller Electric
Mfg.
Co.
CALL:
7~~~jf9~
carner
414-7354505
settling claims,
contact your distributor and/or
Manuals
Circuit And
or
shipment,
.
equipment
Transportation
Department
{TETIT]
U
oj
.
FAX:
(in USA), or
(outside USA)
800-637-2348
414-735-4136
Process Handbooks
Users
Guides
Distributor Directories
WRITE:
Miller Electric
Mfg.
Co.
P.O. BOX 1079
contact your distributor
.
Appleton,
Always provide
Model Name and Serial
or
Style
WI 54912 USA
Number
miller_wan
3/96
Conformity for
European Community (CE) Products
Declaration of
NOTE
This information is provided for units with CE certification
~
Miller Electric
Manufacturers
Name:
Manufacturers
Address:
Declares that the
conforms to the
Mfg. Co.
Spencer Street
Appleton, WI 54914 USA
1635 W.
D64 IVI
product:
following
(see rating label on unit).
Directives and Standards:
Directives
Low
Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC)
Machinery
Directive: 89/336/EEC
Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Arc
Welding Equipment Part I: Welding Power Sources:
(April 1995 Draft Revision)
Arc
Degrees
Welding Equipment:
(May 1995
of Protection Provided
Wirefeed
By
Draft
Systems: IEC
Revision)
Enclosures
(IP Code):
IEC 974-1
974-4
IEC 529:1989
Insulation Coordination For
Part I: Principles,
Equipment With Low-Voltage Systems:
Requirements and Tests: IEC 664-1: 1992
Electromagnetic Compatibility, (EMC):
European Contact:
Mr.
Luigi Vacchini, Managing
Europe S.P.A.
MILLER
Via Privata lseo
20098 San Giuliano
Milanese, Italy
Telephone:
Fax:
dec_coni 1/96
39(02)98290-1
39(02)9828 1 -552
Director
EN 50199
SECTION 1
-
SAFETY PRECAUTIONS FOR ARC WELDING
4/95
safety_Born 1
OM-1587 E 9/96
Symbol Usage
1-1.
4A
Means Warning! Watch
procedure! The possible
Out! There
hazards
are
possible
hazards with this
shown in the
adjoining symbols.
are
Marks
A
a
special safety message.
I
~ Means NOTE; not safety related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary
actions to avoid the hazards.
~
I
________________________________
Arc
1-2.
Hazards
Welding
WARNING
4~
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in the
Safety Standards listed in Section 1-4. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children,
ELECTRIC SHOCK
can
terminal in disconnect box
kill.
electrical parts cart cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine intema!
circuits are also live when power is on. In
semiautomatic or automatic wire welding, the wire,
wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded
equipment is a hazard.
Touching
away.
7.
9.
Turn off all
10. Do not
11. Do not
12. If earth
5.
6.
r.nrrf
nnw~r
r,rntjnrf
wirp
....
~
.
-
ic
nrnnariti
r~onnpt-.torl
.__.__
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can bum eyes and skin. Noise from some
Chipping,
-
,~
-
ear
plugs
or ear
muffs if noise level is
AND
GASES
FUMES
hazardous to your health.
17.
Clamp
remove
3.
4.
welding
area
use
exhaust at the
use an
Read the
Safety
Material
be
2.
Data Sheets
3.
4.
cleaners, and degreasers.
and
body.
do not
is
use
required, ground it directly
clamp or work cable.
work
hamess if
panels and
with
cable
work
working
covers
~
nr yy,Jprstau,c
above floor level.
securely
good
~s near
in
place.
metal-to-metal
thA weld
contact
to
co
a welding helmet fitted with a proper shade of filter to
protect yourface and eyes when welding or watching (see ANSI
Wear
Wear
Use
and
5.
Safety Standards).
approved safety glasses
with side shields.
protective screens or barriers to protect
glare; warn others not to watch the arc.
Wear
others from flash
protective clothing made from durable, flame-resistant
(wool and leather) and foot protection.
the
coatings,
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Work in
Do not weld in locations
operations.
form highly
7.
(MSDSs)
your
workpiece
Z49.i and Z87.1 listed in
arc to
approved air-supplied respirator.
instruction for metals, consumables,
over
of the
material
fumes and gases.
If ventilation is poor,
manufacturers
and/or
poorly spliced
ARC RAYS
6.
If inside, ventilate the
safety
wnrkniet-~
your head out of the fumes. Do not breathe the fumes.
2.
a
Keep
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health,
Keep
grounding
all
16.
Welding produces
1.
cables
separate cable
a
15. Wear
high.
can
or
only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
5.
approved
use.
14. Use
pieces of
NOISE
Use
drape
.._
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
when not in
damaged, undersized,
13. Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
..__.__
can
damage heanng.
processes
grinding, and welds cooling throw off
metal or slag.
1.
with
riroiir~r1
tn
worn,
cables.
dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
4.
equipment
use
a
grounding
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Do not touch live electrical parts.
ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.
Always verify the supply ground check and be sure that input
attach proper
8.
Wear
or
is connected to
double-check connections.
conductor first
1.
the work
plug
outlet.
making input connections,
When
2.
3.
that cord
or
properly grounded receptacle
live
Do not weld
cadmium
near
degreasing, cleaning,
or
spraying
The heat and rays of the arc can react with vapors to
toxic and irritating gases.
on
coated metals, such
plated steel,
weld area, the
area
unless the
as galvanized, lead, or
coating is removed from the
is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
CM-i 587
Page
1
CYLINDERS
2.
3.
Protect
damaged.
4.
high
5.
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
6.
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
8.
Shielding
1.
if
explode
can
gas cylinders
contain gas under
7.
9.
10. Read and follow instructions
in
use or
connected for
associated
equipment,
use.
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
WELDING
can
fire
cause
or
Welding on closed containers, such as tanks,
drums, orpipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and bums. Accidental contact of electrode to metal
objects
or
sure
the
Watch for fire, and
6.
Be
7.
is safe before
area
9.
1.
Protect
2.
Do not weld where
yourself
and others from
flying sparks
flying sparks
can
and hot metal.
10.
strike flammable material.
Remove all flammables within 35 ft
(10.7 m) of the welding arc. If
tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
11.
this is not possible,
Additional Installation,
Operation,
FIRE OR EXPLOSION
unit
on,
over,
combustible surfaces.
1.
Do not locate unit on, over,
surfaces.
2.
Do not install unit
near
12.
or
Do not weld
on
or
partition
the hidden side.
on
closed containers such
as
tanks, drums,
or
And Maintenance Hazards
MOVING PARTS
near
from
can cause
1.
Keep away
2.
Keep away from pinch points
injury.
moving parts.
such
as
drive rolls.
combustible
or near
FLYING PIECES OF METAL
or
DIRT
can
injure eyes.
flammables.
1.
FALLING
EQUIPMENT
can
cause
serious personal injury and equipment
Use
lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
safety glasses
Wear
with side shields
or
face
shield.
4
damage.
1.
fire
pipes, unless they are properly prepared according to AWS F4.1
(see Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighteror matches,
from your person before doing any welding.
result from
can
placing
that
aware
can cause
8.
sparks, explosion, overheating,
can cause
fire. Check and be
keep a fire extinguisher nearby.
welding on a ceiling, floor, bulkhead,
5.
doing any welding.
1-3.
a
a
cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
Install
explosion.
4.
drape
Never allow
mechanical shocks,
circuits.
3.
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
Never weld on a pressurized cylinder
explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
Never
~
WELDING WIRE
wounds.
1.
Do not press gun
2.
Do not
can
trigger
cause
puncture
until instructed to do
so.
point gun toward any part of the body, other
people, or any metal when threading welding wire.
unit.
HOT PARTS
can cause severe
HIGH-FREQUENCY
burns.
interfere with radio
Do not touch hot parts bare handed.
Allow
cooling period before working
on
gun
or
services,
MOVING PARTS
2.
can cause
Keep away from moving parts
Keep all doors, panels, covers,
and securely in place.
as
fans.
FIELDS
can
and
guards closed
FROM
affect
HIGH
using
pacemaker
Have
Pacemaker
arc
OM-1587
Page
2
the
by the FCC
equipment at
the
installation
about interference,
stop
once.
regularly checked
and
maintained.
wearers
keep away.
Wearers should consult their doctor before
near
is
user
electrician
operation.
operations.
equipment.
responsible for having a qualified
promptly correct any interference
problem resulting from the installation.
The
If notified
MAGNETIC
CURRENTS
and
qualified persons familiar with
electronic equipment perform this installation.
injury.
such
can
only
Have
1.
computers,
communications
torch.
RADIATION
navigation, safety
welding, gouging,
or
going
spot welding
Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting,
and use grounding and shielding to minimize the
possibility of interference.
OVERUSE can
EQUIPMENT.
1.
Allow
2.
Reduce current
to weld
Follow rated
or
on
boards
2.
in
Safety
American
capacitors
input power,
according
Maintenance
and
to
before
Section
touchina any Darts.
can
damage parts
BUILDUP OF SHIELDING GAS
health or kill.
strap BEFORE handling
parts.
static-proof bags and boxes
ship PC boards.
or
Use proper
Principal Safety
in
instructions
duty cycle.
wrist
input
discharge
again.
grounded
move, or
1-4.
duty cycle before
can
harm
-
Put
Turn Off inverter, disconnect
1.
reduce
STATIC ELECTRICITY
on circuit boards.
1.
SIGNIFICANT DC VOLTAGE exists after
removal of input power on Inverters.
OVERHEATED
cooling period.
starting
3.
cause
Shut off
1.
to store,
shielding gas supply when
not in use.
Standards
Welding and Cutting, ANSI Standard Z49.1, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Safe
Handling of Compressed Gases
in
Cylinders,
CGA
Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Cutting, CSA Standard W117.2,
Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Code for
from
Safety
in
Welding
and
Standards
Canadian
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National
Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Standards Institute, 1430
New York, NY 10018.
Cutting
NFPA
American
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
And
National Fire Protection Association,
51 B,
from
MA 02269.
Considerations About
To reduce
Electric And
Welding And The Effects Of Low Frequency
Magnetic Fields
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background PapeI OTA-BP-E-53 (Washington, DC: U.S.
there is now a very
Government Printing Office, May 1989):..
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is of
very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
procedures:
.
allow
or
Standard
Batterymarch Park, Quincy,
EMF Information
1-5.
risk
Broadway,
Welding Processes,
us
or
to draw definite conclusions about
to offer clear science-based advice on
avoid
potential
risks.
questions of possible
strategies to minimize
magnetic fields
in the
1.
Keep cables
2.
Arrange
3.
Do not coil
4.
Keep welding power
practical.
source
5.
Connect work
to
close
cables to
or
workplace,
together by twisting
one
taping
side and away from the
drape cables
clamp
or
around the
as
following
them.
operator.
body.
and cables
workpiece
the
use
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The above
wearers.
procedures
are
also recommended for
Consult your doctor for
pacemaker
complete information.
OM-1 587
Page
3
SECTION 1
CONSIGNES DE SECU RITE POUR LE
SOUDAGE A LARC
-
safety_Born_cf r 4195
Signification
1-1.
~
AA
des
symboles
Signifie Mise en garde! Attention! Ce mode opØratoire peut
prØsenterdes dangers! Les dangers possibles sont indiques par
es divers symboles.
I
I
I
1-2.
Dangers
a
du
Indique
A
message de securitC
un
special.
~ signme NOTA; pas lie ala sdcuritØ
I
symbolos signifie Mise en garde! Attention!, risque de CHOCS ELECTRIQUES, dangers prØsentØs par los PI¨CES MOBILES et los PI¨CES CHAUDES. Voir les symboles et Ies
corisignes associØes ci-aprŁs pour prendre los mesures nØcessaires afiri do so prØmurtir contre
les dangers.
Ce groupe de
soudage a
Iarc
MISE EN GARDE
Les symboles donnØs ci-aprŁs sont utilisØs dans tout le manuel pour attirer Iattention sur les dangers
possibles et pour indiquer le type de danger dont ii sagit. Quand on volt le symbole, prendre garde et
suivre les directives correspondantes pour Øviter le danger. Les consignes de sØcuritØ donnØes ci-aprŁs
ne
font que rØsumer Iinformation contenue dans les
toutes ces normes de sØcuritØ.
normes
de sØcuritØ ØnumØrØes a Ia section 1 -4. Lire et
respecter
Linstallation,
lutilisation,
Ientretien
et les
reparations
doivent Œtre confiØs
ne
qu
des personnes
qualifiØes.
Aucune personne, et
UN CHOC
Un
simple
particuliŁrement
les
ELECTRIQUE peut
contact
avec
des
enfants,
piŁces electnques pout
danger.
1.
Ne
2.
Porter des gants et des vŒtements de protection secs no corn
portant pas de trous.
Sisoler de Ia piŁce et do Ia terre au moyen do tapis ou dautres
moyens isolants suftisamment grands pour empŁcher le contact
physique Øventuel avec a piŁce ou Ia terre.
3.
4.
5.
6.
jamais
toucher
es
dolt
tuer.
provoquerune electrocution ou des blessures graves.
LØlectrode et Ie circuit do soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrØe et es
circuits intemes de lappareil sont egalement sous
tension a ce moment-l. En soudage somi-automati
que ou automatique, le fil, le dØvidoir, Ic logement des
galets dentraTnement et les piŁces metalliques en
contact avec le fil de soudage sont sous tension. Des
matØriels ma! installØs ou mal mis ala terre presentent
un
ne
piŁces electnques
sous
7.
proximitØ
cordØ a Ia borne do terre du sectionneur ou que Ia fiche du cor
don est raccordØe a une pnse correctemont mise a Ia terre.
fixer dabord
le
En effectuant los raccordements dentrØe
conductour do miso a Ia terre appropne ot contre-vØnfier los
Verifier frequomment le cordon dalimentation pour voir sil nest
romplacer le cordon immediatepas endommagØ ou dØnudØ
un cable dØnudØ peut provoquer une
mont sliest endommagØ
Mettre
lapparoil
hors tension
ondommagØs,
le cable do rotour.
13.
Ne pas toucher lØlectrode
ou uno electrode
Ia terre
14.
ce
manuel.
hamais de sØcuritØ
quand on travaille en hauteur.
place tous les panneaux ot capots.
Fixer le cable do rotour do facon a obtenir un bon contact metal
metal avoc Ia piŁce a souder ou Ia table do travail, 10 plus prŁs
possible do Ia soudure.
Maintonir solidoment
ciaux ot municipaux.
Toujours verifier Ia terre
17.
ost bien rac
un
LE RAYONNEMENT DE LARC
peut
brler es yeux et Ia peau. Le BRUIT peut
endommager IouIe; les PROJECTIONS
DE LAITIER OU LES ETINCELLES
peuvent blesser les yeux.
RAVONNEMENT DE LARC
Larc do soudage produit des rayons visiblos ot invi
sibles intenses (ultraviolets et infrarouges) qui pouv
ont brUlor los youx ot Ia poau. Le bruit produit par cor
tains procØdŁs pout ondommager louIe. Des projoc
tions do metal ou do laitior sont produitos par 10
piquago, 0 meulago 011 10 refroidissoment dos sou
dures.
Z87.1 donnØos
2.
autre machine.
quun materiel on bon etat. RØparer ou romplacer sur
le-champ los piŁces endommagees. Entretenir lappareil confor
mØment a
Verifier et
quand on est en contact avec Ia piŁce,
provenant dune
Nutilisor
16.
4
lutilise pas.
de grosseur in
Ne pas enrouler los cables autour du corps.
Si Ia piŁce soudØe dolt Łtre mise a laterro, 10 faire directement
no pas utilisor 10 connecteur do piŁce ou
avec un cable distinct
Porter
Page
on no
11.
12.
15.
OM-1587
quand
Ne pas utiliser dos cables uses,
suffisante ou mal ØpissØs.
Installer et mettro a Ia terre corroctemont cot appareil confom,Ø
mont a son manuel dutilisation et au codes nationaux, provin
Utiliser dos bouche-oreilles ou des serro-tŁte antibruit approu
yes silo niveau do bruit est ØlevØ.
soudage
10.
Couper
du cordon dalimentation
sassurer quo le tilde terre du cordon dalimentation
du poste de
electrocution.
9.
en
masque a serro-tØte muni dun vorre filtrant do nuance
pour protegor 0 visago et los yeux quand on soudo
observe Ia travail do soudago (voir los normes ANSI Z49.1 et
Porter
un
appropriØo
ou
sous
Ia
rubrique Principales
normos
do sØcun
te).
3.
Porter des lunottos do sØcuritØ
approuvØes
avoc
Øcrans late-
raux.
4.
Utilisor des paravonts ou dos barnŁros do protection pour protØ
ger les personnes a proximitØ contre los coups darc et IØblouis
semont; avertir es autros personnes do no pas regardor arc.
5.
Porter des vŁtements do protection en tissu
no et cuir) et des chaussures do secunte.
BRUIT
1.
trouver a
connexions.
8.
tension.
lalimentation ou arrŒter le moteur avant de proceder a
installation, ala reparation ou a lentretien do lappareil. DØver
rouiller !alimentation solon Ia norrne OSHA 29 CFR 1910.147
(voir norrnes do sØcuntØ).
se
ignifuge durable (Iai
I
I
I
LES
ET
VAPEURS
Œtre dangereuses
LES
FUMEES
pour Ia
peuvent
5.
Le
1.
Garder
es
2.
3.
4.
a
est
soudage produit des vapeurs
dangereux de respirer.
et des fumØes
tŒte a lextØrieur des vapeurs et des fumØes et
quil
ne
pas
6.
respirer.
espace confine que sil est bien ventilO,
que lair est
et irritants.
Ne pas souder sur des mØtaux revŒtus comme Iaciergalvanise,
au p10mb ou cadmiØ a moms que Ia piŁce nalt ØtØ entiŁrement
dØcapee, que le poste de travail soit bien ventilØ. Sil y a lieu,
un appareil respiratoire a adduction dalr
pur. Les
revŒtements et les mOtaux qui contiennent do tels OlØments
peuvent degager des vapeurs toxiques lors du soudage.
porter
dØgraissants.
exploser Si
ou
un
Ne pas souder a proximitØ doperations de dØgraissage, de
nettoyage ou de pulvØnsation. La chaleur et les rayons do larc
peuvent reagir avec les vapeurs pour former des gaz hautement
toxiques
7.
adduction dair pur approuvØ.
Consulter es fiches signaletiques et es consignes du fabricant
relatives au mØtaux, produits dapport, revŒtements, nettoyants
LES BOUTEILLES peuvent
elles sont endommagØes.
portant
des blessures graves voire mortelles. Sassuror
propre a Ia respiration.
A IintØneur, ventiler le posts de travail ou utiliser un dispositif
place au niveau de larc pour Øvacuer los vapeurs et fumØes de
soudage.
Si Ia ventHation est mauvaise, utiliser un appareil respiratoire a
et
un
appareil respiratoire a adduction dair pur.
Demander a un observateur ayant reu Ia bonne formation de
toujours se tenir a proximitØ. Les vapeurs et fumØes de soudage
peuvent dØplacer lair et abaisser le niveau doxygene et causer
sante.
I
Ne travailler dans
en
4.
5.
Najamais poser un chalumeau soudeur sur une bouteille do gaz.
Ne jamais laisser une electrode de soudage toucher une
bouteille.
Les bouteilles contenant des gaz de protection sont a
haute pression. Une bouteille endommagee peut
exploser. Etant donnØ que les bouteilles de gaz font
normalement partie du materiel de soudage, les
traiteravec le plus grand soin.
1.
2.
3.
les bouteilles de gaz comprimØ contre a chaleur
intense, les chocs, le laitier, les flammes nues, les Øtincelles et
Iarc.
Placer les bouteilles a a verticale en es fixant a un support fixe
ou a un chariot pour Øviter quolles ne tombent ou ne basculent.
Tenir
es
bouteilles a lØcart
du
poste de soudage
le
Replacer
chapeau
Se
personnes a
proximitØ
Ne pas souder dans un endroit o
atteindre des matØnaux inflammables.
Enlever toutes
matiŁres inflammables dans un rayon de
arc. Si cela nest pas possible, bien les
utilisant des bches approuvees.
de
Prendre garde que es Øtincelles et les projections ne pØnØtrent
dans des zones adjacentes en sinfiltrant dans des petites
Autres
ou
dangers
relatifs a
2.
EN
dune
au contact, au-dessus,
surface combustible.
ou
Ne pas installer Iappareil a ctŁ dun objet ou dun
produit inflammable.
TOMBANT, LE MATERIEL peut sen
dommager
ou
causer
des
Nutiliser
lappareil;
riots,
2.
3.
de
sur un
plafond,
oxtincteur a
un
un
plancher,
une
9.
Ne pas utilisor le chalumeau soudeur pour
rubrique Pnncipales
10.
soudage
11.
12.
normes
do
EnleverlØlectrode onrobØe du
au ras
securitØ).
dØgeler dos tuyaux.
porte-electrode ou couperle fil do
du bec contact
quand
on ne
Iutilise pas.
Porter des vŒtements do protection non huileux
gants en cuir, une chemise Øpaisse, des pantalons
dos chaussures montantes et un casque.
Ne pas
porter des matiŁres combustibles
ou
des allumettos
quand
on
sur
comme
dos
sans revers,
soi
comme un
soudo
et Ientretien
PI¨CES
CHAUDES peuvent provo
brlures
des
graves.
quer
LES
1.
2.
No pas toucher les
piŁces
chaudes los mains
LES
pØnode do
pistolet ou Ia
une
PI¨CES
refroidissemont avant do
torche.
MOBILES peuvent
causer
des blessures.
1.
Se tenir a lØcart des
me
piŁces
en
mouvement corn-
los ventilateurs.
quo tous les capots, panneaux, portes
protecteurs sont bien fermØs et fermement
Sassurer
et
que pour soulever
NE PAS Iutiliser pour soulever los cha
Ievage
es bouteilles do gaz ou autres accessoiros.
Pour soulevor Ia source do courant, utiliser des
appareils de puissance suffisante.
Si Ion utilise un ØlØvateur a fourche pour dØplacer
Iappareil, sassurerque Ia fourthe est suffisarnment
et dØpasse de Iautre cotØ do lappareil.
Laissor
toucher le
2.
Ianneau
si Ion soude
toujours avoir
Raccorder lo cable do retour Ia piece, le plus pres possible do
Ia zone do soudage, pour empŒcher quo 10 courant do soudage
ne suive une trajoctoire longue et Øventuellemont inconnue et
quiI no provoque des nsques dØlectrocution et dincendio.
blessures
graves.
1.
incendies et
nues.
combustibles.
Ne pas placer Iappareil
a ctØ
aprŁs utilisation.
8.
ces
1.
Ia bouteille
sur
No pas souder sur des recipients fermØs commo dos reservoirs,
des Wits ou des tuyaux a moms quils no soient prØparØs de facon
appropriee conformement a Ia norme F4.1 do lAWS (voir Ia
Iinstallation, Iutilisation
UN INCENDIE OU UNE EXPLOSION peut
Œtre cause par un appareil place au
contact, au-dessus ou a cote de surfa
des
autre, le feu pout prondre de lautre ctØ.
bnquet a gaz
fissures et ouvertures.
protection,
elle
7.
es
m
aux
rappeler quo
cloison
des Øtincelles
les Øtincelles peuvent
de
gaz
:
Lire et suivre les consignes relatives aux bouteilles de gaz
comprime, au materiel connexe ainsi quo Ia publication P-i do Ia
CGA donnØe sous Ia rubnquo Principales normes do sØcuritØ
6.
recouvnr en
1-3.
10.
Ne pas souder sur des recipients fermØs comme des
reservoirs, des fts ou des tuyaux : Is peuvent
exploser. Larc de soudage peut produire des
Øtincelles. Des Øtincelles, une piŁce chaude et un
materiel chaud peuvent provoquer des incendies et
des blessures. Le contact accidentel de electrode
des objets metalliques peut produire des
sur
Øtincelles, lexplosion, Ia surchauffe ou un incendie.
Sassurerque le lieu ne prØsente pas de danger avant
deffectuer le soudage.
es
de
bouteilles
pression
sous
louvre.
9.
explosion.
protØger et protØger
bouteille
concus pour application particuliere; conserverces matØriels et
leurs piŁces en bon Øtat.
Eloigner le visage de Ia sortie du robinet do Ia bouteille quand on
Prendre garde
proximite.
causer un
une
sur
des
que
5.
moms de 10
4.
8.
dautres
et du metal chaud.
3.
Nutiliser
incendie
LE SOUDAGE peut
Se
ou
Ne jamais souder
exploserait.
dØtendeurs, des tuyaux souples et des raccords appropnes
electriques.
ou une
2.
7.
ProtØger
circuits
1.
6.
maintenus.
LES ECLATS DE METAL ou LES SALE
TES peuvent provoquer des lØs ions aux
yeux.
1.
Porter des lunettes do sØcuritØ
raux ou Øcran facial.
avec
Øcrans late
OM-i 587
Page
5
LES CHAMPS MAGNETIQUES PRO
DUITS PAR LES COURANTS ELEVES
peuvent nuire au fonctionnement du sti
mulateur cardiaque
=9-4
1.
Les personnes qui portent un slimulateurcardiaque
doivent se tenir Øloignees du poste de soudage.
2.
Les personnes qui portent un stimulateur cardia
que devraient consulter leur mØdecin avant de
sapprocherdun poste de soudage ou de gougea
go a arc ou de soudage par points.
LELECTRICITE STATIQUE peut endom
mager es piŁces des circuits imprimØs.
1.
2.
circuits_imprimes.
_________________________
FREQUENCE peut crØer ~es
interferences dans les systŁmes de ra
dionavigation, les services de sØcutitØ,
LA HAUTE
les ordinateurs et le materiel de tØlØ
communications.
1.
Attendre
~HFJ
instructions avant
es
dappuyer
sur
2~
ii,
Ia
3.
gchette.
2.
Ne pas pointer le pistolet sur une partie du corps,
dautres personnes, ou sur une piŁce mØtalli
lorsquon
enfile le fil de
4.
soudage.
?
5.
installa
Tenir los portes et panneaux do Ia source do haute
frØquence bieri fermØs, maintenir les Øclateurs au
rØglage et utiliser une mise a Ia terre et un
protection atm do rØduire au minimum Ia
possibilitØ dinterfØrences.
bon
RØduire le courant ou le facteur de marche avant
de recommencer a souder.
UNE TENSION C.C. IMPORTANTE est
Utiliser le facteur de marche nominal.
prØsente sur les onduleurs aprŁs
lon ait coupØ Ialimentation.
une
penode
de ref roidissement.
Quand
nutilise pas le gaz de
le robinet de Ia bouteille.
on
normes
protection,
Recommended Safe Practice for the Preparation for Welding arid
Cutting of Containers That Have Held Hazardous Substances,
normeAWS F4. 1, de lAmerican Welding Society, 550 N.W. Lejeune
Rd. Miami FL 33126
National Electrical Code, NFPA Standard 70, de Ia National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
NOTA DonnØes
sur
le
magnetiques
les
sur
soudage et sur
basse
hors
es
mettre londuleur
piŁces,
Avant de toucher los
que
tension, coupor lalimentation
et
dØcharger
condensateurs dentrØe conforrnØment
aux
di
rectives de Ia section Entretien.
de sØcuritØ
Safety and Health Sandards, OSHA 29 CFR 1910, du
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Informations
1.
fermer
Safety in Welding and Cutting, norme ANSI Z49.i, de lAmencan
Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i de Ia Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
de sØcuritØ en soudage, coupage et procØdØs connexes,
CSA Wi 17.2, de IAssociation canadienne de normalisation,
vente de norrnes, 178 Rexdale Boulevard, Rexdale (Ontario)
Canada M9W 1 R3.
Regles
norme
Safe Practices For
And Educational
Occupation
Eye
And Face
Protection, norme ANSI Z87. 1, de lAmencan National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51 B, do a National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
champs ØlectromagnØtiques
effets des champs Ølectn-
es
Pour rØduire lintensitØ des champs
magnØtiques au poste de travail:
frequence.
citation tirØe des conclusions
gØnØrales du document Biological Effects of Power Frequency Electric & Magnetic Fields Back
ground Paper (Effets biologiques des champs electnques et magnetiDocument de base), OTA-BP
ques aux froquences dutilisation
-E-53 (Washington, DC: U.S Govemment Printing Office, mail 989)
publtØ par Office of Technology Assessment (Congres des EtatsUnis): ..... des experiences au niveau cellulaire et des etudes sur
lhomrrie et lanimal nous ont apporte une foule de renseignements : II
est maintenant clair que les champs magnØtiques basse frØquence
peuvent influer sur les systŁmes biologiques et les modifier. Ces tra
vaux sont gØnØralement dexcellente qualitØ, mais les rØsultats obteune
regulierement
Laisser
Principales
Void
Faire vØnfier et entretenir
1.
1.
ques et
avertissement dinterfØrence
Øcran de
LACCUMULATION
DE GAZ DE PRO
TECTION peut Œtre nuisible a Ia sante
voire mortel.
1-5.
dun
cas
2.
3.
1-4.
resultant de linstallation.
Dans 10
tion.
UNE UTILISATION EXCESSIVE peut se
traduire par une SURCHAUFFE DU MA
TERIEL.
?
dintrfØrences
donnØ par le Conseil fØdØral des communications,
arrOter dutilisor immØdiatement lequipement.
sur
que
qua un personnel qua
lØquipement electronique.
Lutilisatour ala responsabilitØ de faire comger ra
pidement par un Ølectncien qualifiØ les problŁmes
No confier cette installation
liflØ et connaissant bion
LE FIL DE SOUDAGE peut percer Ia peau.
1.
un
ler los cartos de circuits
LES PI¨CES MOBILES peuvent provo
quer des blessures.
Se tenir a lØcart des piŁces mobiles.
1.
2.
Se tenir a lØcart des points de pincemen t, ex. : ga
lets dentraInement.
bracelet antistatique AVANT de
manipu
impnmØs ou los piŁces.
Utiliser des sacs et boites antistatiques adequats
pour ranger, dØplacer ou expØdier les cartes do
Mettre
1.
Grouper
solidement les cables
en
es
entrelaant
ou en
les
serrant avec un ruban adhØsif.
-
2.
Disposer les cables
sur un
seul ctØ
et a lØcart
de
lopØra
-
complexes. Dans lØtat actuel de nos connaissances dans le
domaine scientifique, nous ne sommes pas en mesure dinterpreter
nus
sont
nos
observations a
a
lumiŁre dune thØorie
gØnerale. Et.
cc
qui est
plus regrettable, nous ne pouvons nen affirmer de dØfinitif au
sujet des nsques Øventuels, ii proposer des mØthodes scientiflques
encore
precises pour rØduire
OM-1 587
Page
6
ces
nsques
ou
pour
es
Øviter.
teur.
3.
4.
Eviter
les cables
Eloigner
de
5.
denrouler
le plus possible Ia
soudage.
ou
source
Raccorder le connecteur de
prØs possible
Stimulateurs
de les poser
sur
lØpaule.
de courant et los cables
piŁce a
Ia
piŁce
a souder, le
plus
de Ia soudure.
cardiaques:
Les recommandations cl-avant sadressent aussi, normalement,
aux personnes qul utilisent un stimulateur cardiaque. Pour de plus
amples renseignements, consultez votre mØdecin.
SECTION 2- DEFINITIONS
2-1.
Warning
Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Drive rolls
injure fingers
can
Welding wire and drive parts are at
welding voltage during operation
keep
hands
and
metal
objects
clear.
1
Electric shock
1.1 Wear
kill.
can
dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet
or
damaged gloves.
1.2 Protect
from electric
yourself
shock by insulating yourself
from work and ground.
1.3 Disconnect
input plug
working
or
power before
machine.
2
on
fumes
Breathing welding
can
be hazardous to your health.
2.1
Keep your head Out of the
fumes.
2.2 Use forced ventilation
exhaust to
2.3 Use
remove
ventilating
or
local
the fumes.
fan to
remove
fumes.
3
Welding sparks
explosion
3.1
Keep
or
can cause
fire.
flammables away from
Dont weld near
welding.
flammables.
3.2
Welding sparks
can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld
on
drums
or
any
closed containers.
4
Arc rays can bum eyes and
injure skin.
4.1 Wear hat and
safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete
body
protection.
5
Become trained and read the
instructions before working
on
6
the machine
or
Do not
remove or
(cover)
the label.
welding.
paint
over
OM-1 587
Page
7
2-2.
Manufacturers
Rating
Label For CE Products
For label location
Section 3-4.
see
ST-178 794-A
2-3.
And Definitions
Symbols
NOTE
).~.
~
Some
symbols
are
found
Output
Alternating Current
()
Off
Duty Cycle
O~O
Jog
>
Purge
()
~
I.
U2
Load
1 f\~_,
OM-1 587
Page
Voltage
Single
8
Phase
on
CE
A
p
Parameter Select
Read Instructions
Increase
only
products.
Amperes
Degree
Of
Protection
Trigger
~b
~J
Volts
Hz
Hertz
~J ~f
Trigger
Trigger Hold On
Trigger Hold On
IndicatorLight
0
Trigger Hold Off
IndicatorLight
Primary Current
12
Rated Current
Line Connection
(J1
O,/~
Hold Off
Primary Voltage
Percent
SECTION 3- INSTALLATION
3-1.
Site Selection
3-2.
Gun Recommendation Table
Process
GMAW-P
GMAW
FCAW
Hard
Hard
or
or
Gun
Cored Wires
Cored Wires
Self-Shielding
Wires
GW-500 Or GW-600
M25, M40, Or GA-50C
GA-4OGL Or GA-5OGL
OM-1 587
Page
9
3-3.
Equipment Connection Diagram
1
300/400 Ampere Model
CC/CV Inverter Welding
Power Source
f~ Use switch settings shown for
pulse welding. Change
switch
to CV for other wire feed weld
ing processes.
2
450
Ampere Model CCICV
Inverter
Welding
Power
Source
~jf
Use switch
all
~
~D~IZ
shown for
feed
welding
processes.
3
owl
settings
wire
17-Pin Cord
4
14-Pin Cord
5
Positive (+) Weld Cable
6
Negative ()
Be
sure
Weld Cable
weld cables are sized
for peak amperage if
properly
pulse welding (see welding power
source Owners
Manual).
7
Workpiece
8
Voltage Sensing
9
Gun
Lead
Be sure gun is rated for peak
amperage if pulse welding. Install
according to its Owners Manual.
10
Wire Feeder
3
ST-i 62129 / Ref. ST.i 54 197/ ST-146 127-C / Ref. ST-163 420-A
OM-1 587
Page
10
3-4.
3-5.
Rear Panel Connections
14-Pin
12]
*The
3-6.
Plug
Information
~j~*
REMOTE 14
remaining pins
are not
17-Socket
Pin Information
A
24 volts ac with
B
Contact closure to A
G
Circuit
C
+10 volts dc
0
Remote control circuit
E
0 to +10 volts dc
I-I
Voltage feedback;
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
respect
common
to socket G.
completes
24 volts
ac
contactor control circuit.
for 24 volts AC circuit.
output
to remote control with
respect
to socket D.
common.
input command signal from
remote control with
0 to +10 volts dc, 1 volt per 10
arc
respect to socket D.
volts.
used.
Receptacle Information
Socket Information
CC/CV select; +13 to +24 volts dc is CV, 0 volts dc is CC.
Arc control/inductance control; 0 to +10 volts dc.
Actual weld amperage
Actual weld
Circuit
*The
remaining sockets
are
output signal;
voltage output signal;
+1 volt dc is 100 amps.
+1 volt dc is 10 volts dc.
common.
not used.
OM-1 587
Page
11
Wire
3-7.
Motor
Type, Size,
Speed
Wire
All
Standard
Au
Standard
All
Optional High
All
OM-1587
Rotating
Page
12
Speed Capability
The Drive
Table
Feed
Wire Size
Type
Standard
3-8.
And Feed
.023 To 5/64 in
3/32 To 7/64 in
(0.6 To
1/8 in
(2.4
mm)
To 2.8
mm)
(0.6 To
50 To 780
1pm (1.3 To 19.8 mpm)
50 To 700
1pm (1.3 To
50 To 300
(3.2 mm)
.023 To 5/64 in
Assembly
2
Speed Capability
2
mm)
92 To 1440
17.8
mpm)
1pm (1.3 To 7.6 mpm)
ipm (2.3 To 35.6 mpm)
3-9.
Installing
And
Threading Welding
Wire
ri~d~ *4
Install
wire
anti-wear
guides
and
guide.
If necessary, move hub and spool
so wire runs straight from
support
the
spool through
the drive rolls.
Install wire spool. Adjust tension nut
so wire is taut when wire feed stops.
1~
Install drive rolls.
-,
NONCONDUCTIVE
SURFACE
No Wire
Be
sure
that outlet cable has proper
welding wire size.
ff~
Wire
Slips
Forsoft wire orsmalldiameterstainless
size liner for the
steel wire,
When
roll pressure from 0 to a maximum of 4
on the pressure indicator scale (so that
only the inner spring is compressed).
This setting will generally give the best
performance for these types of wires.
installing gun, position liner
extending from outlet wire guide as
close as possible to drive rolls without
touching.
Install gun. Lay gun cable out straight. Cut
oft end of wire. Push wire through guides up
to drive rolls; continue to hold wire. Press
Jog
Slip
NONCONDUCTIVE
SURFACE
To
use
2 drive rolls and set drive
adjust drive roll
pressure, hold nozzle
about 2 in
(51 mm)
from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire does
slip. Do not overtighten. If contact tip is
completely blocked, wire should slip at the
feeder (see pressure adjustment above).
not
Cut wire off. Close
cover.
button to feed wire out gun.
Tools Needed:
:::~~:~z~
~
~
3~16,5~64
~
in
15/16,3/Bin
Ref. ST.1 56 929 1 Ref. SC.1 50 922 / Ref. ST.1 56 930 / S-0627-A
aM-i 587
Page
13
SECTiON 4- OPERATION
4-1.
Operational
NOTE
The
following
Terms
See Menu Guide for detailed
~
is
a
list of terms and their definitions
as
programming steps.
they apply
to this wire feeder:
General Terms:
Adaptive
Pulse
arc
Cold Wire
automatically regulates pulse frequency to maintain
length, regardless of change in welding wire stickout.
The wire feeder
Welding
constant
a
When weld amperage is not present, wire feeds for about three seconds at set
wire feed speed. Then the welding power source contactor deenergizes and
Jog
wire continues to feed at the wire
Inductance
As inductance
more
Trim
Arc
arc on
jog speed.
time increases, and the weld
puddle
becomes
fluid.
length adjustment
length.
Synergic
increases,
Trim is
in
pulse welding. Increasing
trim increases the actual
arc
replaced by volts in MIG programs.
The operator programs
for a specific wire feed speed. The
pulse parameters between these wire feed speed
pulse parameters
wire feeder determines the
increments.
Side Panel Terms:
Card Mode
Is used to select
use
Dual Schedule Mode
Is used to select
a
Process Mode
Is used to select the
Pulse,
Sequence
Mode
or
of the optional data card storage and retrieval
pair of programs that
type of process
can
to be
be used
capabilities.
together.
used, including Pulse, Adaptive
Mig.
Is used to select and program the weld sequences which include weld, crater,
burnback, postflow, preflow, and run-in.
4-2.
Pulse
Welding
Terms
1
Apk
Peak
=
Amperage
Increasing Apk increases penetra
tion.
2
Abk
Background Amperage
=
Maintains
3
I
/ ~
Time
Page
14
=
between
pulses.
Pulses Per Second
Increasing PPS increases
speed.
3
Amps
OM-1 587
PPS
arc
I:c;:si:re~
travel
bead
4-3.
Front Panel Controls
8
7
4
5
5
6
ST-182 127
click
1
Display
2
Parameter Select Button
Press button to
3
move > on
causes program number
crease/decrease by one.
display.
Display Control
Turn control to
change
value
pointed
to
by
When 1PM is selected,
click causes wire feed
crease/decrease
by
turning control one
speed (1PM) to in
to increase
When
Prg
by
# is
0.1.
selected, turning control
release gun
Side Select Button
Jog
Schedule Mode (see Section 6).
Push to
Pulse is
process
use side
default setting. To change type of
(Pulse, Adaptive Pulse, or MIG)
panel controls.
a
4
Active Side Indicator
5
Trigger Hold Button And
Light
Light
Indicator
holding gun trigger through
cycle, press and release button to
feature on (indicator light turns on).
out weld
turn
trigger within
cycle, press and release gun
three seconds after an arc has
out
cycle, press and
trigger.
7
To start weld
one
been struck. To end weld
6
To weld without
one.
MPM
is selected, turning control
three clicks causes wire feed speed (MPM)
When
to in
The program number cannot be changed
while welding, with exception of Dual
>.
Turning control one click causes Trim (arc
length) to increase/decrease by one or Volt
to increase/decrease by 0.1.
(Prg #)
Button
momentarily feed welding wire with
energizing welding circuit or shielding
gas valve.
Jog speed is varied using the Display Con
trol while Jog button is pressed. Default set
ting is 200 1PM.
8
Purge Button
Push to momentarily energize gas valve
without energizing the welding circuit.
Holding the Jog and Purge buttons atthe
same time displays pulse parameters on
the side panel display and voltage on
front panel display.
OM-1587 Page 15
4-4.
Side And Rear Panel Controls
1
Mode
2
Mode Select Button
Display
Press button to move> in
display.
3
Parameter
4
Parameter Select Button
Press button to
Display
move >
in
display.
5
Parameter Increase Button
6
Parameter Decrease Button
7
Power Switch
8
Circuit Breaker CB1
CB1 protects the wire feeder from
overload.
O~~6
J
Ref. ST-162 128 / Ref. ST-i 62 133
OM-1 587
Page
16
SECTION 5- SETTING SEQUENCE PARAMETERS
See Menu Guide for detailed
programming steps.
arc length. It set to zero,
length is short. If set to 99,
length is long.
Trim is
arc
arc
It time is set to zero in Weld
sequence, welding continues until
gun trigger is released.
If time is set to
zero
in any timed
the
Weld,
except
sequence is skipped.
sequence
A
Weld Time
a
a
0.
025
sec.
Cl)
U
a
~
U)
U
a
LL
~
Prettow
Time
Crater
Time
Bumback
Time
Run-In
Time
/
a
Cu
/
0
Time
/
Time
Bumback
Run-In
Preflow
Arc
Strike
Weld
Trigger
Pressed
Released
Pulse
Trim
Volts
Inductance
1PM
0-99
10.0-38.0
0-99%
50-780
X
0-25.0
Pulse
X
X
X
X
X
Crater
0-2.50
MIG
3.
Seconds
X
Weld
MIG
2.
Sequence
End
Trigger
1.
Postflow
Crater
Bumback
X
X
MIG
0-025
x
Only
4. & 5. Postflow/
0-9.9
Preflow
Pulse
6.
=
X
0-2.50
MIG
X
X
Run-In
Sethng
X
X
available.
OM-1 587
Page
17
SECTION 6- SETTING DUAL SCHEDULE PARAMETERS
6-1.
Selecting
Dual Schedule Pair
Dual Schedule is used with two
consecutive weld programs 1 & 2,
3 & 4, 5 & 6, or 7 & 8. Any program
type (MIG, Adaptive Pulse, or
Pulse) can be combined in dual
schedule.
1
Side Panel
Display
Use side panel to tum feature on.
See Menu Guide for detailed
programming steps.
2
Front Panel
Press front
Display
panel parameter select
button to select program number.
3
Front Panel
4
Dual Schedule Switch
Section
Control
Display
(See
6-2)
~ Switch type is set in
System
Setup.
5
Welding
Gun
Trigger
Selecting dual schedule program A
or B is done by using Display Con
trol, dual schedule switch,
trigger
setup).
(depending
on
or
gun
system
When program B is active, turn
Display Control one click clock
wise to select another
pair of
dual
schedule programs.
~ Programs can be rearranged
in desired order using the data
card.
2
24.
250
OV
1PM
-3
4
Display
Control
OM-1587
Page
18
>Prg
3
Dual
A
6-2.
Dual Schedule Switch
Diagrams
1
Momen2P
(Momentary-Contact 2-Pole
Switch or DSS-1O)
>2
2
2
Maint 2P (Maintained-Contact
2-Pole Switch or DSS-9M)
3
Maint 1 P Or
2
2
Trigger
(Maintained-Contact 1-Pole
Switch, DSS-9, Or DSS-8)
A
3
1
2
>
0
A
~ If
3
>
0
trigger
schedule
is
used
switch,
for
dual
turn off
Trig
Program Select in system
ger
setup.
4
B
0
4
0
3
1
1
Adapter
1
>
2
2
TR
>
3
___________
I
3
>
~
(~0~
2
2
>
3
1
1
>
3
Adapter
2
>
3
>
>
A\~~>
4
1
>
2
>
3
>
4
>-
SECTION 7- USING THE OPTIONAL DATA CARD
7-1.
Data Card Terms
CARD SCREEN TERMS
WRITE
Programs
To Card
~
READ
Programs
From Card
PULSE MIG TERMS
pPS
Amperage
(Pulses Per
Second)
PWms
Is
(Pulse Width In
Milliseconds)
-r
Apk (Peak
Amperage)
Abk
(Background
Amperage)
Time
SA-158 435
OM-1587
Page
19
7-2.
Installing
Data Card
1
Label
Apply label
to data card. Write pro
gram information
2
Data Card
3
Card Slot
on
label.
For Blank Data Card:
Insert card into slot. To format card,
turn On power. Select Card from
menu.
Data card formats when unit
enters Card mode.
3
For Power Source Data Card:
Insert card into slot. Turn On
power. Push Parameter Select but
ton within 3 seconds and the 8 pro
grams and setup information are
read into the wire feeder memory.
Unit is
Wait
ready
to use when
front
Please
from
disappears
panel display.
message
ST-i 56 266-B
7-3.
Card
Displays
See Menu Guide for detailed
programming steps.
1
Card
2
Moving
Display
Line
Moving line is
be changed.
under value that
can
Process
3
Sequence
DualSchd
>Card
Write
Transfers program data from unit
to card. The program card can hold
up to 32 programs. When writing to
the card, the next available pro
Press
Be low
gram number is automatically
as
signed.
Side Panel
Parameter
Select Once
3
4
Read
Transfers program data from card
to unit.
5
Delete
Deletes program data from card.
6
4
Done
Exits card
5
OM-1587
Page
20
display.
SYSTEM SETUP
SECTION 8
NOTE
See Menu Guide for detailed
~
programming steps.
DISPLAY
NOTES
SETTiNG
*
>System
>Range
Select the process the
*
welding
power
is able to do.
source
power source minimum and maximum voltage values are always needed. Amper
age values are required for pulse welding. Set values to match welding power source
ranges.
Welding
>Security,
>Access
With lock on, volts
or tnm
When on, restricts
use
Be
>Mig Type
and
ipm range of change
of setup
be restricted.
screens.
voltage sensing leads are connected
welding power source.
sure
can
or
voltage feedback
is available
through 17-pin
connection to
When system setting is Mig Only, V.Sense is automatically selected. Use V. Sense when
more than 50 ft (15m) of weld cable is used (including gun cable length).
>Voltage
>Arc Start**
>Dual Schedule
Use Hot Start
only
ter wires. The
arc
See Section 6-2. If
When on,
>Trigger
preflow
Ampere Inverter
Model
welding
power
source
and
large
diame
Trigger
is used for dual schedule switch, turn Off
Trigger Program
Select.
trigger can be used to switch between programs that have at least 0.2 seconds of
programmed. Cannot be used in combination with Trigger Dual Schedule.
time
When on,
>Remote
with 450
starts in CV and switches to CC.
the front
a
DSS-1 0
can
panel display>
be used to
change
Volts
or
Trim, 1PM,
or
Prg depending
on
where
is.
>Arc Time
See Section 11-3.
>Self Test
>Wire Feed
Choose to
display
inches per minute
or
meters per minute.
Pulse programs differ between bench and boom models.
>Model**
Reset: unit defaults to
original factory setting
for the last active program.
System Reset: unit defaults to original factory settings
System, Arc Time, and Model.
for all programs and setup
Program
>Memory
Setup
in
formation does not change.
>Shutdown
When on, the system immediately shuts down if
feeds even if no arc voltage is sensed.
When on,
>Name
>Software
*
Automatically
Can be used
**
optional
Know this when
data card programs
talking
with service
can
no arc
voltage
excluding
is sensed. When off, wire
be named.
personnel.
set if power source data card is used.
only
when
optional data
on display
Selection does not appear
card is inserted.
when MIG
Only
is
System
choice.
OM-1587
Page
21
SECTION 9- STANDARD PULSE WELDING PROGRAMS
Apk
=
Peak Amperage, Abk =
Background Amperage, PPS
Program
Wire
Size/Type:
.035
ER 70S-3
Gas: 98Ar -2
Oxy
=
1
or
Pulses Per Second, PWms
95 Ar -5
Apk
Abk
PPS
PWrns
750/19.1
470
100
160
2.3
700/17.8
460
100
150
2.3
650/16.5
450
100
145
2.3
600/15.2
440
100
140
2.3
550/14.0
430
95
135
2.3
500/12.7
420
90
130
2.2
450/11.4
410
85
125
2.1
400/10.2
400
80
120
2.0
350/8.9
390
75
110
2.0
300/7.6
370
70
100
1.9
250/6.4
350
65
90
1.8
200/5.1
330
60
80
1.7
150/3.8
320
55
60
1.6
100/2.5
300
45
40
1.6
80/2.0
290
40
35
1.5
Wire
Size/Type:
.045
ER 70S-3
Gas: 9BAr
-
2
Oxy
2
or
95 Ar
Apk
Abk
PPS
PWms
750/19.1
540
120
220
3.2
700/17.8
530
120
210
3.2
650/16.5
520
120
200
3.1
600 /15.2
510
115
190
3.0
550/14.0
500
115
180
3.0
500/12.7
490
115
170
2.9
450/11.4
480
110
160
2.8
400/10.2
470
105
150
2.7
350/8.9
460
100
140
2.6
300/7.6
450
95
130
2.5
250/6.4
440
85
120
2.4
200/5.1
420
80
100
2.3
150 / 3.8
400
75
80
2.2
100/2.5
350
62
60
2.1
80/2.0
320
60
50
2.1
Page
22
(milliseconds).
Oxy
/40 CFH
(19 Urn)
Gun: MILLER GW
COMMENTS
Steel
1PM I MPM
OM-1 587
Pulse Width
Steel
1PM I MPM
Program
=
-
5
Oxy
/ 40 CFH
(19 Urn) Gun: MILLER
COMMENTS
GW
Program
Wire
Size/Type:
.052
ER 70S-3
Gas: 98Ar -2
Oxy
3
Steel
or
95 Ar -5
1PM I MPM
Apk
Abk
PPS
PWms
750/19.1
565
145
260
3.1
700/17.8
565
140
260
3.1
650 /16.5
560
135
260
3.1
600/15.2
560
130
255
3.1
550/14.0
560
125
240
3.1
500/12.7
550
120
225
3.0
450/11.4
540
115
210
2.9
400/10.2
530
110
195
2.9
350/8.9
520
105
170
2.8
300/7.6
510
100
155
2.8
250/6.4
500
95
140
2.7
200/5.1
480
90
120
2.6
150/3.8
460
70
100
2.5
100/2.5
420
50
80
2.4
50/1.3
350
35
50
2.4
Program
Wire
Size/Type:
.035
Gas: 98 Ar
ER 309
-
2
4
CO2
Oxy
/ 40 CFH
(19 Urn)
Gun: MILLER GW
COMMENTS
Stainless
or
95Ar
1PM I MPM
Apk
Abk
PPS
PWms
750/19.1
390
95
210
2.2
700/17.8
380
95
200
2.1
650 / 16.5
370
90
190
2.0
600/15.2
360
85
180
1.9
550/14.0
350
80
170
1.9
500/12.7
340
75
160
1.9
450/11.4
330
70
150
1.8
400/10.2
320
65
140
1.8
350/8.9
310
60
130
1.7
300/7.6
300
55
120
1.7
250/6.4
290
50
100
1.6
200/5.1
280
45
80
1.6
150/3.8
270
40
60
1.6
100/2.5
270
36
40
1.5
80/2.0
260
30
30
1.5
-
5
CO2
/ 40 CFH
(19 Urn)
Gun: MILLER GW
COMMENTS
OM-1 587
Page 23
Program
Wire
Size/Type:
.045
ER 309
Gas: 98 Ar
-
2
5
CO2
Stainless
or
95Ar
1PM / MPM
Apk
Abk
PPS
PWms
750/19.1
490
110
260
2.3
700/17.8
480
110
260
2.3
650/16.5
470
105
260
2.2
600/15.2
460
100
240
2.1
550/14.0
450
100
240
2.0
500 /12.7
440
95
220
1.9
450/11.4
430
95
200
1.9
400/10.2
420
95
180
1.9
350/8.9
410
95
160
1.8
300 / 7.6
400
90
140
1.8
250/6.4
380
85
120
1.8
200/5.1
360
80
100
1.7
150/3.8
340
70
80
1.6
100/2.5
320
50
60
1.6
80/2.0
320
45
45
1.6
Program
Wire
Size/Type:
3/64
ER 4043
Gas:
6
Abk
PPS
PWms
750/19.1
510
145
190
3.5
700 / 17.8
500
145
180
3.5
650/16.5
480
140
180
3.4
600/15.2
470
140
180
3.3
550/14.0
460
140
170
3.2
500/12.7
440
135
160
3.0
450/11.4
420
130
150
3.0
400 / 10.2
380
130
140
2.9
350/8.9
350
115
130
2.8
300/7.6
320
105
120
2.7
250/6.4
280
93
110
2.6
200/5.1
250
73
100
2.4
150/3.8
230
52
90
2.2
100/2.5
205
32
80
2.2
80/2.0
190
25
45
2.2
24
Co2
Argon /40 CFH (19 LIm)
Apk
Page
5
/40 CFH
(19 Urn)
Gun: MILLER GW
COMMENTS
Aluminum
1PM I MPM
OM-1 587
-
Gun: MILLER GW
COMMENTS
Program
Wire
Size/Type:
3/64
ER 5356
Gas:
Argon
7
Aluminum
/40 CFH
(19 Urn)
1PM / MPM
Apk
Abk
PPS
PWms
750/19.1
540
130
190
2.9
700/17.8
520
125
190
2.8
650/16.5
500
120
180
2.8
600/15.2
480
115
170
2.8
550/14.0
460
110
160
2.7
500/12.7
440
100
150
2.7
450/11.4
420
90
140
2.7
400/10.2
390
85
130
2.6
350/8.9
370
70
120
2.4
300/7.6
355
55
110
2.3
250/6.4
335
45
100
2.2
200/5.1
310
35
90
2.2
150/3.8
272
33
90
2.0
100/2.5
262
24
60
2.0
50/1.3
230
18
40
1.8
Program
Wire
Size/Type:
.035
Nickel
Alloy
Gas: 75 Ar
8
-
Nickel
COMMENTS
Alloy
25 He / 40 CFH
1PM / MPM
Apk
Abk
PPS
PWms
750/19.1
390
110
130
3.5
700/17.8
380
105
130
3.5
650/16.5
370
100
125
3.4
600/15.2
360
90
120
3.4
550/14.0
350
85
115
3.3
500/12.7
345
80
110
3.3
450/11.4
340
75
105
3.3
400/10.2
330
70
95
3.3
350/8.9
320
65
85
3.3
300/7.6
310
60
75
3.2
250/6.4
300
55
65
3.1
200/5.1
290
48
55
3.1
150/3.8
275
42
45
3.1
100/2.5
250
31
35
2.9
50/1.3
220
25
30
2.8
Gun: MILLER GW
(19 Urn)
Gun: MILLER GW
COMMENTS
OM-1 587
Page
25
SECTION 10
10-1. Teach Points
-
TEACH POINTS
Explained
The teach mode allows the
custom
create
user
to
pulse programs.
The teach mode has 15 teach
points. At each teach point, the
user can adjust five parameters to
shape the pulse waveform of the
output. The five parameters
(MPM), Apk, Abk, PPS,
weld
Apk
=
Peak
Amperage
are:
1PM
and PWms.
~
Abk
o
PPS
Background Amperage
=
Apk, Abk, PPS, and PWms acting
together provide the energy neces
sary to bum oft welding wire ata set
wire feed speed. The graph below
shows that as wire feed speed in
creases, energy increases (Apk,
Abk, PPS, and PWms acting
synergically).
Pulses Per Second
PWms
Pulse Width
(Milliseconds)
Under
some
conditions, the wire
feeder limits wire feed speed to
pulse parameters with
capability of the system.
maintain all
in the
1PM!
780
750/19.
700 / 17
650 / 1
600 / 1
550! 1
500/12.
450!11~
Example Of A Synergic
Sethng For 425 1PM With
400 / 11
All Teach Points Set At 50
(1.3 MPM) Increments
1PM
350/8.~
300!7~
250/6.
200/5.1~
150!
100 / 2.
50
Apk
100
180
210
240
270
300
330
360
370
420
450
480
510
540
565
Apk
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
140
200
Abk
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
365
400
PPS
PWms
OM-1 587
1
Page
2
26
3
4
5
PWms
10-2.
Redefining
Teach Points
~
1PM detem,ines the weld metal
deposition
~
Redefining
rate.
Redefining 1PM is not normally
required unless special wire or
is
unusual
joint
design
1PM Teach Point
needed.
Use front
___________________
Trim
50
Prg
1PM
>450
1/
Purge
~
1
move>
Display
Control
____________________
select teach
there
are teach points at 150,200,
and 250 ipm; the teach point at 200
can be adjusted to a wire feed
speed of 151 to 249 1pm.
Ar~d
1PM
to
Press and hold Purge button while
turning Display Control to redefine
the 1pm teach point. For example:
Prg
1
2
Apk
Peak
3
Abk
Background Amperage
Peak and
>460
select
to select 1PM. Use
point value.
Pulse
Trim
50
panel parameter
button to
_______________
Pulse
depend on
Amperage
background amperage
the range of the welding
________________
power
source.
4
PPS
Pulses Per Second Of
20-400
5
PWms
Pulse Width Of
1.0-5.0 Milliseconds
Use side
Redefining
Pulse Parameters
pulse
panel
controls to
change
See
Menu
parameters.
Guide for detailed
programming
steps.
After values are set, strike and
maintain an arc for five seconds.
Do this for each teach point.
End weld
not
by releasing gun trigger,
by pulling gun out of weld. Re
peat for each
custom teach
The
point.
taught arc length represents
Trim (arc length) setting of 50.
2
a
Once the teach points are set, the
wire feeder adjusts parameters
between teach points synergically.
5
--3
1PM
340
>70
160
340
Apk
340
Apk
Apk
70
Abk
70
Abk
Abk
>160
PPS
160
PPS
PPS
1.4
PWms
>1.9
PWms
__________
__________
Ref. S-0259 I Ref. ST-154 109
OM-1 587
Page
27
Date______________ Program Number
Wire
Gas
SizeiType
CFH(LJmin)
Flowrate
Power Source______
Serial Number
Wire Feeder_______________________
Serial Number
Equipment
Used
Gun Model________________ Weld Cable
Negative
Wire Manufacturer__________
1PM /
Apk
Abk
Mfg.
PPS
PWms
Vpk
Date
COMMENTS
MPM
Pref low Seconds:__________
Run-In TrimNolts:__________ 1PM / MPM:____________________ Seconds:____________________
Crater Volts:______________ 1PM I MPM:_____________________ Seconds:____________________
Postf low Seconds:_________
OM-1 587
Page
28
SECTION 11
-
MAINTENANCE AND TROUBLESHOOTING
11-1. Routine Maintenance
CM-i 587
Page
29
11-2. Error
Displays
*4
i
i
r
r
gge
I
I
Release
2
L
S
s
e
d
Memo
r
y
e
1Error
Volt
No
n
3
Prg
CRC
Error
Memory
Prg
Range
Error
4
N
o
Tach
Sensed
Er
ro
r
Er
ro
r
Erro
r
6
Arc
Start
7
Arc
Stop
Ref. ST.1 55 222
1
Release
Trigger
Error
Display
This appears if the trigger is closed when
the unit power is turned on, or if the trigger
is stuck
or
defective.
No Volt Sensed Error
The
arc
feedback.
ing
connections.
Display
circuit is not receiv
Check voltage sensing
sense
Check
connections
17-position plugs/receptacles
and welding power source.
Turn unit off and back
on
at the
at
unit
after
correcting
error
continues to
Memory CRC
OM-1 587
Page
system
Memory Range
Error
30
occur
when
pulse
to select Hot Start.
Error
Display
This appears when pulse welding and cur
rent is detected but the arc cannot be
started. Check and correct program pulse
parameters and voltage settings. Check
voltage sensing connections.
reset.
Display
Press front
panel Parameter Select
to clear
error.
Go through pulse parameters to make sure
they do not exceed settings of the Range
display or perform a system reset.
No Tach Sensed Error
The motor tach feedback is not
Press front
reaching the
panel Parameter Select
error.
6
Arc Start Error
7
Arc
Stop Error Display
This appears when pulse welding and the
motor does not stop at the end of the weld.
Display
If there is
high frequency being
prob
to clear
Press front
Display
used in the
area, turn it off. A motor brake circuit
lem can also cause this error.
control. Check connections.
welding, it may help
3
a
The data in the program indicated is out of
usable range.
5
problem.
If this
Perform
4
2
voltage
The data in the program indicated is not the
same data that was saved.
error.
panel Parameter Select to clear
Using
11-3.
Self Test
A
only Factory-Autho
perform tests
replace parts.
Have
rized persons
or
1
Switch A
gun
switch
gun
switch
This checks the
increase position.
2
Switch B
This checks the
decrease position.
Press
Mode
Select
3
Tnggor
This checks the gun
trigger.
1
4
Wire Feed
Gun
This checks the wire feed motor.
5
Gas
This checks the gas valve.
6
Contactor
This checks the
source
7
welding power
contactor.
CVICC
This tests the pin at the 17-pin
receptacle that controls whether
the unit is in CC (constant current)
or
CV
(constant voltage).
-~
Off
Press
~
>cQnIg~IQrl
I..0 f f
P
r
e s ~
Side Panel
Parameter
Select
Increase
A
The
welding
wire and all metal parts In contact
~
withitcarryweldoutputwhentheweldingpower source
contactor is
energized.
On
p
r
e s s
OM-1 587
Page
31
11-4.
Troubleshooting
Disconnect power before
A
Trouble
troubleshooting
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding power source contactor do not
Check and reset CB1
interconnecting
cord connections. If secure, check cord for
continuity and repair or replace (see
Sections 3-3 and 3-4).
(see
Section
4-4).
pull in.
Electrode wire feeding stops
erratically during welding.
or
feeds
Check gun
trigger connection. See gun Owners
Check gun
trigger. See gun Owners
Readjust hub
Change
Clean
or
replace dirty
Incorrect size
Replace
Have
Motor
runs
leased, and trigger hold is
possible
feed speed.
Unit does
not
erratic
switch
Check for
or
spatter
or worn
wire
(see Section NO TAG).
(see Table 13-1).
drive roll.
guides.
liner. See gun Owners
or
foreign
Manual.
matter from around nozzle
Authorized Service
Agency
opening.
check drive motor
or
motor control board PCi.
input voltage.
a
short between
welding gun trigger
leads arid weld cable.
Repair short
or
replace welding
a
short between
welding gun trigger
leads and weld cable.
Repair
or
replace welding
gun.
not on.
Gas valve in feeder is rattling loudly
with
Factory
tip
Check for correct
slowly.
Wire does not feed until trigger is pulled,
but continues to feed after trigger is re-
along
or worn
contact
Remove weld
Manual.
tension and drive roll pressure
to correct size drive roll
Manual.
or
out
slow wire
of
Run-In
Check for
short
gun.
Install, reconnect,
or
replace voltage sensing lead.
~
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
OM-1 587
Page
32
light
Check
welding
gun
trigger
leads for
continuity,
and
repair leads
or
replace gun.
NOTES
OM-1587 Page 33
SECTION 12- ELECTRICAL DIAGRAM
~T?T
~
t~ Wff~ SWtG~
~T*O~4T ~rD4
~ ~I
I2~
24~2~2>-~
v~
_________________
74~<7~7~<I I74~
3~<I3~<2.E-~43)-~<l
)~
.7
ax
3
H
r()~
~ 11<
~ lO(
I
7<
~r
4(2
~1
Ic~
I E~.-.z~.E-~45)-~4d
~
~II~_______
~ 12 (
(rx2)~-<1+~-<l ~ >~<I I ~
~
_~____–~v_<3*~_<I3 ~
I
I
-
P.42
Figure
OM-1 587
Page
34
12-1. Circuit
Diagram
ax
~
V
II
II
<1~~~<fl~
11>~~~<
~
~E-2-< ~ )~-<
~
~
.~_L.< 4.E-~44 >_L<
~
For Wire Feeder
H
(
2
ax
Cl:
Wn~ aqa
(.34vc4)
~I-C
> T,tV
~PC
> patina ~U~)
WS
> VU.TMZ F~l
c>4
(lvjt.J
(w/vv)
C
Ic >+
a)>
a
u).>
~
~
pcw
Lar4~ina J
=
DSP
~-l
~
a,.
~ STW
I
___
Q9V1
~~a
2>
~
I
I
~
SD-164 539-D
OM-1587
Page
35
SECTION 13- PARTS LIST
CD
LI)
C
C
\
/
C,,
0)
U-
(~t~
C)
1
C)
0)
U-
CD
E
a,
Cl)
a,
-D
C-,
c~J
C
c,)2,
LI~
ST-BOO 0B4-D
Figure
OM-1 587
Page
36
13-1. Main
Assembly
Item
No.
Part
No.
Figure
13-1. Main
Assembly
4
124900
REEL, wire 60 lb (consisting of)
NUT, spanner retaining
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
SUPPORT, reel spool
5
143160
HUB & SPINDLE ASSEMBLY,
6
058427
7
180573
8
010233
1
.108008
2
168103
3
+168 104
166594
9
057971
10
010191
11
058628
12
058428
139226
BASE
22
083639
23
159360
24
159646
25
159647
...26
139752
27
167768
WEATHERSTRIPPING, adh .125 x 1.500 (order by if)
INSULATOR, screw machine
CLAMP, motor base
INSULATOR, motor clamp
SPACER, stl .500 OD x l2ga wall x 3.750
DRIVE ASSEMBLY, wire RH (Fig 13-4)
DRIVE ASSEMBLY, wire RH (high speed) (Fig 13-4)
CLAMP, motor top
STRIP, buna N compressed sheet .062 x 4.000 x 4.000
HOSE, SAE .187 ID x .410 OD
DRIVE ASSEMBLY, wire LH (Fig 13-4)
DRIVE ASSEMBLY, wire LH (high speed) (Fig 13-4)
135205
601964
16
141411
17
134306
18
142838
19
602213
27
167770
28
156243
...29
145639
30
125473
167762
.167764
32
1
1
1
1
RING, retaining spool
SHAFT, support spool
SPRING, cprsn .970 OD x .120 wire x 1.250
WASHER, flat .632 ID x 1.500 OD x .1 25thk stl
WASHER, flat .656 lOx 1.500 OD x .l25thk fbr
601872
14
1
1
(consisting of)
WASHER, brakestl
HUG, spool
TUBING, stl .875 00 x l2ga wall x 2.375
NUT, .625-11 .g4hex .77 high stl elastic stop
SCREW, .375-16 x .750hexhd
SUPPORT, spool
FOOT, rubber 1 .25Odia x 1 .375high
BRACKET, mtg spool RH
WASHER, lock .380 ID x .683 OD x .ll5thk stl split
NUT, .375-16 .56hex .34 high stl
071730
Quantity
Description
1
1
1
2
2
2
1
1
1
2
1
4
1
2
2
1
Figl3-2
CONTROL BOX
600 324
CABLE, weld cop strd No. 4/0 (order by if)
ift
8
2
2
1
1
1
2
2
2
1
1
1
3ft
OPTIONAL
When
ordering
a
component originally displaying
a
precautionary label,
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 587
Page
37
N
0
A
0)
A
I
/
0)
N
C)
0)
LL
4,
0)
0
ii-
C)
e
C)
C)
C
C)
C)
C)
ST-800 111-B
Figure
OM-1 587
Page
38
13-2. Control Box
Dia.
Item
No.
Mkgs.
Part
No.
Figure
161 707
2..:..GS1,2.... 125785
134201
PCi
155 114
PLG1....
115092
PLG2....
115093
PLG4....
115091
PLG6....
136810
161 706
CB1
8
..
083432
Si
111 997
PC8O, RC81
163921
PLG75
131 204
PLG82
PLG9O
158720
11
13-1 Item
32)
1
PANEL, side lower
VALVE, 24VAC 2 way custom port 1/8 art
STAND-OFF SUPPORT, PC card .3121.375
CIRCUIT CARD, motor control
2
10
1
CONNECTOR&SOCKETS
CONNECTOR & SOCKETS
CONNECTOR&SOCKETS
CONNECTOR & SOCKETS
1
1
1
1
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1P 1OA 250V
1
1
SWITCH, rocker SPST 1OA 25OVAC
CIRCUIT CARD, HF filter dual
1
1
153501
073756
STAND-OFF, 6-32
2
151 187
LATCH, slide flush mtg hole 1.000 wide
134464
178936
163519
141 162
079 739
PLG19
(Fig
1
010325
PLG9....
13-2. Control Box
CONNECTOR&SOCKETS
CONNECTOR&SOCKETS
CONNECTOR&SOCKETS
+161 710
13
Quantity
Description
x
.625
1
1
lg
x
1.500
1
Ig
WRAPPER
1
BUSHING, strain relief .840 ID x .875mtg hole
LABEL, warning general precautionary
LABEL, warning general precautionary CE
CABLE, port No. 18/14 8/c (order by if)
CON NECTOR & PINS, (consisting of)
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
1
1
1
12ff
1
1
603106
CONNECTOR & SOCKETS
CLAMP, univ 50A
HOSE, nprn brd No. 1 x .250 ID (order
600 399
WIRE, strd l4ga blk 600V 105c (order by if)
138044
107983
BUSHING, strain relief .120/.150 ID
BLANK, snap-in nyl .SOOmtg hole
048282
CONNECTOR w/SOCKETS
1
...23
000 527
...24
605 227
BLANK, snap-in nyl .875mtg hole
NUT, .750-14 knurled 1.68dia .41 high nyl
RELAY,encI24VACDPDT
2
158719
601 222
19
...22
RC7O....
...25
CR101
072817
...26
SRi
035 704
...27
030170
Fig
29...
PLG12,50
13-3
155629
154938
097132
.32
.34
PC5O....
PLG51
PLG52
PLG53
PLG54
PLG55
PC1O
PLG11.
PLG15
PLG17
35...
36...
PLG1O,24
PLG16,41
163917
RECTIFIER, integ 40A 800V
BUSHING, snap-in nyl .750 ID
PANEL, front w/components
CABLE, ribbon l4posn
STRIP, mtg PC card
STAND-OFF, 6-32 x .375 Ig
158720
CIRCUIT CARD, interface
CONNECTOR & SOCKETS
158719
CONNECTOR & SOCKETS
131 204
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
148439
115092
126689
STAND-OFF, 6-32
161 781
CIRCUIT CARD,
CONNECTOR &
CONNECTOR &
CONNECTOR &
115092
153501
115093
170980
155023
Fig
13-5
158373
097868
116964
600 343
097 866
x
1.500
x
1
1
1ff
by if)
35ff
.500mtg hole
1
1
1
1
1
x
1
.000mtg
hole
3
1
1
1
4
1
....1
Ig
processor w/proms.
SOCKETS
1
SOCKETS
1
SOCKETS
1
CABLE, ribbon 34posn
CABLE, ribbon 24posn
PANEL, side w/components
CABLE, interconnecting pwr (consisting of)
CONNECTOR, circ l7skt plug Amphenol MS-3106A-20-29S
CONNECTOR, circ clamp slf sz 20-22 Amphenol MS-3057-1012
CABLE, port No. 16 5/c (order by if)
CONNECTOR, circ 17 pin plug Amphenol MS-3106A-20-29P
1
1
1
1
1
..
OM.1 587
2
10ff
1
Page
39
Dia.
Item
No.
Mkgs.
Part
No.
Figure
059 712
010 145
164059
+When
ordering
a
Quantity
Description
..
..
..
13-2. Control Box
(Fig
13-1 Item
32) (Continued)
CLIP, component .437dia mtg adh back
2
CLAMP
1
nyl
.500
clamp
dia
HOSE ASSEMBLY, gas
component originally displaying
a
precautionary label,
1
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
CM-i 587
Page
40
167697
Item
No.
Dia.
Mkgs.
Part
No.
Figure
1
..
147 139
164 842
144 844
6
....
PC2O,30
171 814
PLG25
165 484
Quantity
Description
13-3.
Panel, Front w/Components (Fig 13-2 Item 28)
NAMEPLATE, (order by model and serial number)
PANEL,front
TAPE, adh acrylic double sided .010 x .500 x 3.000
METER LENS, w/gasket
STAND-OFF~ 6-32 x .875 lg
CIRCUIT CARD, schd front
10
179 201
11
153 169
010 291
CONNECTOR&SOCKETS
See Figure 13-2 Item 35
RING, ext .625 shaft grv x .O45thk E
WASHER, shldr .612 ID
LENS, LED 4345 green panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
13
167 700
KNOB, pointer
PLG24....
...8
159 264
167 633
1
1
2
1
9
1
1
style
1
1
4
6
1
1
3
4
2
£0
13
12
11
ST-800112-C
10
Figure
13-3. Panel, Front
w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 587
Page
41
18
14
See Table 13-1 For
Drive Roll & Wire Guide Kits
21
20
13
9
4
23
24
25
33
27
6
30
28
5
4
3
2
ST-152 711-0
Figure
OM-1 587
Page
42
13-4. Drive
Assembly,
Wire
Item
No.
Part
No.
Dia.
Mkgs.
Figure
1
.010668
2
.172075
3
149962
4
149486
5
132750
6
150520
7
133493
8
133350
9
9
M1,2
M1,2
156354
...
156
353
153491
153492
153493
155098
10
31)
4
4
2
2
2
1
1
1
1
2
2
1
1
1
5
2
1
1
CONNECTOR&SOCKETS ..:.
115092
131 203 ...CONNECTOR&PINS
CONNECTOR & PINS
135 409
11
182414
12
182415
..13
137248
14
129351
602200
604772
182156
1
1
1
WASHER, flat
PIN, cotter hair
SPRING, indicator
SCREW, hexwhd-slt stl slffmg 8-32x .500
WASHER, lock sti split No. 8
...WASHER,flatstlSAENo.8
SPRING, cprsn .573 OD x .088wire x 1.062 Ig
1
1
1
1
1
2
1
SPRING
18
182155
19
132746...
20
...
2
BUSHING, spring
182 522
SHAFT, spring
132747...CARRIER,shaft
133 739
WASHER, fIat .375 ID x .625 OD x .062
183 330... KNOB, extension
CIRCUIT CARD, digital tach (consisting of)
153 631
1
1
1
...
23
24..
13-1 Items 27 &
COVER, motor gearbox (consisting of)
GASKET, cover
SCREW, cover
SPACER, locating
RING, rtng ext .250 shaft grv x 025thk
133493
22
(Fig
2
154031
16
Wire
PIN, rotation arm rocker
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft x .O25thk
PIN, hinge
MOTOR, gear 11Bhp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
155100
...
Assembly,
4
155099
...
13-4. Drive
SCREW, cap stl sch .250-20 x 1.500
CARRIER, drive roll w/components 24 pitch
SPACER, carrier drive roll
153550
PLG11,17
PLG51,57
RC7,8
Quantity
Description
TK1 ,2/PC51
PLG57
..
....
CONNECTOR & SOCKETS
604 311
GROMMET, rbr
....
.250 ID
26
149959... FITTING, brs barbed M
27
179 625
...
27
179 624
...
...
28
108 940...
29
604 538
30
151 437...
31
128237...
...
179263...
601872...
34
602213..
35
602243..
...36
601966..
167387..
168825..
133308..
178937..
Optional High Speed
x
OPTICAL ENCODER DISC
132 611
...38
1
...
131 204....
25
32
1
1
.375mtg
1
hole
1
.
.~
3/l6tbg
x
1
.312-24
1
ADAPTER, gun/feeder LH
ADAPTER, gun/feeder RH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstc T 1.125 Ig x .312-18 x 1.500 bar
SCREW, hexwhd-slt stl slftmglo-32 x .500
COVER, drive roll
NUT, stl hex full .375-16
WASHER, lock stl split .375
WASHER, flat stl .375
SCREW, cap stl hexhd .375-16 x 1.250
SPACER, locating
DRIVE, pinion 40T 24P .376 bore
RING, retaining ext .375 shaft x .O25thk
LABEL, warning electric shock
1
4
1
1
2
2
1
1
1
~
1
2
1
1
1
Motor
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1587
Page
43
Dia.
Item
No.
Part
No.
Mkgs.
Description
Figure
1
147139
2
155024
3
154933
13-5.
P~neI,
Side
w/Components (Fig
TAPE, adh acrylic double sided .010
LENS, clea~r anti-glare
PANEL, inr~er qontrol
153501
CIRCUIT CARb, data card
CONNECTOR&SOCKETS
158160
CIRCUIT
7
144844
STAN
8
154109
PLATE, identipner control
9
153169
P060
PLG6O
PLG41
PC4O
4
6
156623
:
See
....
Figure.13-2,
CARD,
ACTUATOl~,
x
.500
x
13-2 Item
37)
2
3.000
1
1
1
1
Item 36
side
6-32
D-OFr,
Quantity
x
1
display
Ig
4
.875
1
.s~itch
4
~4.
7
:~
4
9
=
Figure
1
3-5.~Panel,
BE SURE TO PROVIDE MODEL AND SERIAL
Page
44
Side
r~UMBER
~
OM-1 587
ST-BOO 113-B
w/Components
WHEN ORDERING REPLACEMENT PARTS.
Table 13-1. Drive Roll And Wire Guide Kits
.!
~
Wire Size
~5
V-GROOVE
U-GROOVE
0
0
4 Roll
Kit
Drive
Roll
4 RoIl
Kit
Drive
Roll
151036
072000
151052
132958
053697
151037
053701
151053
151028
053698
151038
053702
151029
053699
151039
053706
4 Roll
Drive
Kit
Roll
132957
151070
083489
151054
132956
151071
083490
151055
132955
151072
053708
151 056
132959
053704
151 057
132960
151 073
053710
151041
053703
151058
132961
151074
053709
149521
151 042
053705
151 059
132962
151 075
053711
149522
151043
053707
151060
132963
151076
053712
Drive
Roll
149518
151024
087130
150993
149518
151 025
053695
0.9mm
150993
149518
151026
053700
.O4Oin.
1.0mm
150993
149518
161 189
053696
.045in.
1.1/1.2mrr
150994
149519
151027
.052in.
1.3/1.4mrT
150994
149519
1.6mm
150995
149520
1.8
mm
150995
149 520
(.079in.)
2.0mm
150995
149520
151 040
(
2.4mm
150996
149521
2.8mm
150996
3.2mm
150997
Metric
.023-.025in
0.6mm
150993
.030 in.
0.8
mm
.035in.
.068-072 in
UC-GROOVE
4 RoIl
Kit
Fraction
VK-GROOVE
E~
~
5/64 in.
(ibm.)
(i25in)
.
S-0549-
Each Kit Contains An Inlet
Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32
x
.125, Along
With 4 Drive Rolls.
2 Kits Required For Dual Models.
OM-1 587
Page
45
OPTIONS AND ACCESSORIES
WELD CURRENT SENSOR
RPS-8 REMOTE PROGRAM
(#160 963)
Required when using
SELECTOR
ordered for EACH side of the feeder.
the 64M
feeder with Miller conventional
MIG power
have 17pin
sources
Note:If water kit Is to be used on both
sides of a dual wire feeder, a kit must be
that do not
receptacle.
(#160 977)
Eightposition rotary switch used
to remotely select weld programs.
Includes a 33 ft. (10 m) cord.
WATER HOSE KIT
Y
(#165 491)
Required
CONTROL DETACHMENT KIT
POWER SOURCE DATA CARDS
Data card is inserted into feeder,
and with a push of a button, the
feeder is
automatically
programmed for the power
being
source
used. Each data card
contains
kit
MIG Power Sources:
(#164
(#164
(#164
(#164
(#164
(#164
assembly
Data Card for Pulse MIG and
Conventional MIG Power
Source:
For .035
-
.045 in.
(0.9
-
includes
eight synergic pulse
programs:
(#141 580)
-
1/8 in.
(1.6-3.2 mm)
DUAL SCHEDULE SWITCHES
wire
DSS-8
(#141 581)
For lOft.
(3 m)
(#079 691)
Reduces cast in wire.
Improves
feeding performance and
wire
(3 m) gun
(#079 693)
tip.
contact
Requires adapter cord (#157 364).
Twoposition trigger switch that
easily attaches to the welding gun.
Used in place of the standard
trigger for dual scheduling.
HIGH-SPEED MOTOR
For
single
and
right
gas
.045 in. steel wire with
Argon/Oxygen shielding
gas
.035 in. 309L stainless steel
using Argon/CO shielding gas
.045 in. 309L stainless steel wire
side of dual
(#132 129) Factory only
For left side of dual wire models.
(#132 130) Factory only
speed range of 90
1400 1PM (2.3 35.6 rn/mm.). Not
recommended for wire sizes larger
than 5/64 in. (2.0 mm).
lmportant:Same speed motor
used
on
models.
Blank Card
programs and transferring
programs to other 64M feeders.
(4.6 m) gun
(#041 793)
must be
slide switch that
Two-position
attaches to the
Pulse
MIG programs will not operate with
WATER HOSE KIT
(#155 910)
For 15 ft.
Factorywritten synergic
using Argon shielding gas
3/64 in. 5356 aluminum wire
Stores up to 32 complete weld
programs. Ideal for saving custom
(3 m) gun
(#041 792)
For 10 ft.
each side of the dual wire
highspeed
MM DATA CARD
DSS-9M
-
using Argon/CO shielding gas
3/64 in. 4043 aluminum wire
using Argon shielding gas
.035 in. nickel wire using
Argon/Helium shielding gas
.035 in. silicon bronze wire using
Argon shielding gas
gun
For 15 ft.
increases life of gun liner and
-
Argon/Oxygen shielding
gun from
overheating by shutting down
system if water does not flow.
mm)
Provides wire
.035 in. steel wire with
WATER FLOW SAFETY SWITCH
Protects watercooled
1.1
for XMTfi 300 CC/CV
XMT 300 CC/CV data card
one
system.
Used with the water hose kits.
models.
(#164 166)
water hose
(#164 583)
and base.
WIRE STRAIGHTENER
For 1/16
162) for Deltaweldfi 300
161) for Deltaweldfi 451
160) for Deltaweldfi 651
163) for Dimensionfi 400
164) for Dimensionfi 650
165) for XMTfi 200 CC/CV
a
dual wire
water coolant
wire
Data Cards for Conventional
a
feeder. Connects both kits to
eight factorywritten
programs and 24 unused spaces
for customerdeveloped programs.
using
10 ft.
feeder control module from the
wire drive
when
each side of
25 ft.
(3 m)
(7.6 m)
For 64M bench models only.
Fieldinstalled only. Separates the
(#134 934)
(#134 935)
on
motor.
For
benchstyle feeders
(#096 746)10 ft. (3m)
For 12 ft. (3 m) Swingarc style
feeders
Selects
welding gun.
welding condition when
utilizing the dual schedule feature.
Gun trigger operates as standard
trigger.
DSS-10 REMOTE INCREASE!
DECREASE SWITCH
(#159 288) 23 ft. (7 m)
For 16 ft. (4.9 m)Swingarc style
Two-position, momentary
contact
feeders
switch that attaches to the
welding
(#159 289)
27 ft.
(8.2 m)
Used with Miller coolant systems
and GW Series watercooled
welding guns. Can be used with or
without optional water flow safety
switch.
(#042 749)
gun. Used with the Remote
Parameter Increase/Decrease
feature to fine tune parameters at
the welding gun while welding.
Gun trigger operates
trigger.
as
standard
I IiO~
OPTIONS AND ACCESSORIES
HANGING BAIL
WIRE REEL ASSEMBLY
MILLER GMAW
(#058 435)
(#108 008)
Accommodates 60 lb.
(27 kg)
coil
of wire.
Electrically
feeder
WaterCooled
isolated.
over
work
Suspends
coil
of wire. For left side of D64M
TURNTABLE ASSEMBLY
dual
wire model.
(#146 236)
of D64M
dual wire
changes
work
strain and
model. Protects wire from
as operator
position. Reduces
bending
of gun cable.
WATER COOLANT SYSTEMS
Radiator 1A, 115 VAC
(#042 492)
gal. (5.7 L)tank capacity.
contaminants.
ADJUSTABLE SPOOL CARRIER
(#091 668)
(#096 075)
SPOOL COVERS
a
12 in.
Guns
Refer to literature Index No. M/9.0.
Allows feeder to rotate
(#058 256)
For right side
Fits
Guns
Refer to literature Index No.
AirCooled
(27 kg)
GUNS
Mu 3.4.
area.
REEL COVERS
Accommodates 60 lb.
(MIG)
(304 mm) spool
of
with
dual
of D64M
only with Swingarc models
6 ft. (1 .8 m) pipe post
mounted
wire model.
dual wire
on
lower for easier
CARRYING CART
loading
Carries wire feeder and
miscellaneous
welding supplies.
Height: 34 in (863 mm). Lower tray
height: 9 in. (228 mm). Shipped
and
disassembled.
(18 m) from power
14Pin
4
cart.
Shipped
17Pin
(#042 495)
gal. (7.6 L)
tank
capacity.
(#042288)
gal. (15.1 L)
tank
capacity.
Refer to Water Coolant
Systems
literature, Index No. AY/7.2.
source.
Extension Cord
(#122 973) 25 ft. (7.6 m)
(#122974)50 ft. (15 m)
FEEDER CART
2
CooImate~ 4, 115 VAC
For optimum performance, do not
extend 64M feeder more than 60
ft.
1A, 115 VAC
WatermateTM
wire
EXTENSION CORDS
(#056 301)
(#042 493)
gal. (5.7 L) tank capacity.
1 .5
base.
unloading.
(#090 389)
disassembled.
Swingpak
Replaces standard spool
assembly. Positions welding
model.
(#142 382)
Lowprofile, creeper
Radiator 2A, 230 VAC
Used
wire. For left side of D64M
(#057 607)
For right side
1.5
Extension Cord
(#042 120)
25 ft.
(7.6 m)
COOLANT SOLUTION
(For Extra Freezing Protection)
(#128 705)
Resists freezing to 00 F (18
C).
Important:
Distilled water is recommended.
11 ~
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